Sand screen for downhole operations

ABSTRACT

A sand screen includes a tubular having an outer surface, and a plurality of filter features arranged on the tubular and defining a plurality of openings. Each of the plurality of filter features is defined by a plurality of louvers having an angled surface portion that extends axially along the tubular.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of an earlier filing date from U.S.Provisional Application Ser. No. 62/537,729 filed Jul. 27, 2017, theentire disclosure of which is incorporated herein by reference.

BACKGROUND

In the resource recovery and exploration industry, it is often desirableto filter downhole fluids passing into a tubular. For example, it may bedesirable to filter out larger sand particles while allowing fines topass into the tubular. There are a variety of techniques employed tofilter fluids passing into a tubular. Operators may employ gravelpacking techniques or sand screens. Gravel packing techniques includingpacking a layer of gravel around a portion of the tubular. The layer ofgravel acts as sieve allowing fines to pass into the tubular whileentrapping larger sand particles. While effective, gravel packing is anexpensive and time consuming process and thus a less desirable option.

Sand screens include one or more layers of mesh or other screeningmaterial arranged about a tubular. The tubular is positioned at adesired depth and production is initiated through the sand screen. Thescreening material may be selected to allow passage of some particles,such as fines, while preventing passage of other, larger, particles.Over time, the screening material may become clogged with an impermeablefilter cake. Clogging of the screening material may result in a smallerflow area that could lead to hot spotting and, ultimately, screenfailure.

SUMMARY

Disclosed is a sand screen including a tubular having an outer surface,and a plurality of filter features arranged on the tubular and defininga plurality of openings. Each of the plurality of filter features isdefined by a plurality of louvers having an angled surface portion thatextends axially along the tubular.

Also disclosed is a sand screen including a tubular having an outersurface, and a plurality of filter features arranged on the tubular anddefining a plurality of openings. The plurality of filter features isdefined by a wire wrap having an outer surface portion having a compoundsurface including an angled surface portion that extends axially alongthe tubular.

Further discloses is a method of screening downhole fluids includingdirecting the downhole fluids axially along a sand screen, passing thedownhole fluids across a plurality of filter features that extendangularly outwardly of and axially along the sand screen, establishing aselected fluid velocity of the downhole fluid based on at least an angleof the filter feature and particulate in the downhole fluids, andguiding a portion of the particulate through openings defined betweenthe plurality of filter features while excluding another portion of theparticulate.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 depicts a resource recovery and exploration system including asand screen, in accordance with an aspect of an exemplary embodiment;

FIG. 2 depicts a tubular including a sand screen, in accordance with anaspect of an exemplary embodiment;

FIG. 3 depicts a cross-sectional view of a plurality of filter featuresof the sand screen of FIG. 2, in accordance with an aspect of anexemplary embodiment;

FIG. 4 depicts a tubular including a sand screen, in accordance withanother aspect of an exemplary embodiment; and

FIG. 5 depicts a cross-sectional view of a plurality of filter featuresof the sand screen of FIG. 4, in accordance with another aspect of anexemplary embodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

A resource recovery and exploration system, in accordance with anexemplary embodiment, is indicated generally at 2, in FIG. 1. Resourceexploration and recovery system 2 should be understood to include welldrilling operations, resource extraction and recovery, CO₂sequestration, and the like. Resource exploration and recovery system 2may include a surface system 4 operatively connected to a downholesystem 6. Surface system 4 may include pumps 8 that aid in completionand/or extraction processes as well as fluid storage 10. Fluid storage10 may contain a drilling fluid or completion fluid (not shown) or otherfluid which may be introduced into downhole system 6.

Downhole system 6 may include a downhole string 20 formed from aplurality of tubulars, one of which is indicated at 21 that is extendedinto a wellbore 24 formed in formation 26. Wellbore 24 includes anannular wall 28. One of tubulars 21 includes a sand screen 40 having aplurality of filter features 44. Specifically, sand screen 40 and filterfeatures 44 form part of a tubular 48. Filter features 44 are designed,as discussed herein, to allow fines to pass into downhole string 20 fromformation 26 while excluding larger particles in a manner that reducesscreen clogging and impermeable filter cake formation.

Reference will now follow to FIGS. 2 and 3 in describing sand screen 40in accordance with an aspect of an exemplary embodiment. Filter features44 may be take the form of a plurality of louvers (not separatelylabeled) defined by a plurality of raised portions 54 that define acorresponding plurality of openings 56. Each raised portion 54 includesan angled surface portion 58 that extends axially along, and angularlyoutwardly of, tubular 48. In accordance with an exemplary aspect, angledsurface portion 58 extends at an angle 60 of between about 5° and about45°. In accordance with another aspect of an exemplary embodiment,angled surface portion 58 extends at an angle 60 of between about 15°and about 30°.

In accordance with an aspect of an exemplary embodiment, fluid flowvelocity along tubular 48 may be controlled based on the particularangle 60 of angled surface portion 58, aspects of the downhole fluid,and direction of flow. That is, depending on particle size, a ratio offines relative to other particles or the like, and angle 60 of angledsurface portion 58, a bean-up protocol may be established to create aselected tangential flow into tubular 48. The selected tangential flowensures that fines in the downhole fluid pass into openings 56 whilelarger particles flow over angled surface portion 58 without creating animpermeable filter cake at sand screen 40.

Reference will now follow to FIGS. 4 and 5 in describing a sand screen68 in accordance with another aspect of an exemplary embodiment. Sandscreen 68 includes a plurality of filter features 70 supported by atubular 74. Filter features 70 may be defined by a wire wrap (notseparately labeled) bonded to a plurality of struts, one of which isindicated at 78, of tubular 74. Each of the plurality of filter features70 is spaced from an adjacent filter feature to form an opening 79 andincludes an outer surface portion 81 having a compound surface and aninner surface portion 83 that is defined by an apex of an angle 85formed by a first side 87 and a second side 88.

First side 87 includes a first angled surface section 90 and a secondangled surface section 91. Second side 88 includes a third angledsurface section 93 and a fourth angled surface section 94. Theparticular angles formed by first and second, and third and fourthangled surface sections 90, 91 and 93, 94 may vary and could depend uponparameters of the downhole fluid.

In accordance with an aspect of an exemplary embodiment, outer surfaceportion 81 includes a first angled surface portion 97 and a secondangled surface portion 98. Second angled surface portion 98 extendsaxially along and angularly outwardly of tubular 74. In accordance withan exemplary aspect, second angled surface portion 98 extends at anangle 100 of between about 5° and about 45° relative to first angledsurface portion 97 and/or tubular 74. In accordance with another aspectof an exemplary embodiment, second angled surface portion 98 extends atan angle 100 of between about 15° and about 30°.

In a manner similar to that described above, flow velocity of downholefluids along tubular 74 may be controlled based on the particular angleof second angled surface portion 98, aspects of the downhole fluid anddirection of flow. That is, depending on particle size, a ratio of finesrelative to other particles, or the like, and the angle of second angledsurface portion 98, a bean-up protocol may be established to create aselected tangential flow into tubular 74. The selected tangential flowensures that fines in the downhole fluid pass into openings 79 whilelarger particles flow over second angled surface portion 98 withoutcreating an impermeable filter cake at sand screen 68.

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application. For example, “about”can include a range of ±8% or 5%, or 2% of a given value.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1

A sand screen comprising: a tubular having an outer surface; and aplurality of filter features arranged on the tubular and defining aplurality of openings, each of the plurality of filter features beingdefined by a plurality of louvers having an angled surface portion thatextends axially along the tubular.

Embodiment 2

The sand screen according any prior embodiment, wherein the plurality oflouvers include a plurality of raised portions that define acorresponding plurality of openings.

Embodiment 3

The sand screen according to any prior embodiment, wherein the pluralityof raised portions extend at an angle of between about 5° and about 45°relative to the outer surface of the tubular.

Embodiment 4

The sand screen according to any prior embodiment, wherein the pluralityof raised portions extend at an angle of between about 15° and about 30°relative to the outer surface of the tubular.

Embodiment 5

A sand screen comprising: a tubular having an outer surface; and aplurality of filter features arranged on the tubular and defining aplurality of openings, the plurality of filter features being defined bya wire wrap having an outer surface portion having a compound surfaceincluding an angled surface portion that extends axially along thetubular.

Embodiment 6

The sand screen according to any prior embodiment, wherein the compoundsurface of the outer surface of the wire wrap includes an outer surfaceportion having a first angled surface portion and a second angledsurface portion, the second angled surface portion extending at an angleof between about 5° and about 45° relative to the first angled surfaceportion.

Embodiment 7

The sand screen according to any prior embodiment, wherein compoundsurface of the outer surface of the wire wrap includes an outer surfaceportion having a first angled surface portion and a second angledsurface portion, the second angled surface portion extending at an angleof between about 15° and about 30° relative to the first angled surfaceportion.

Embodiment 8

The sand screen according to any prior embodiment, wherein the wire wrapincludes an inner surface portion, a first side extending between theinner surface portion and the outer surface portion, and a second sideextending between the inner surface portion and the outer surfaceportion.

Embodiment 9

The sand screen according to any prior embodiment, wherein the firstside includes a first angled surface section and a second angled surfacesection distinct from the first angled surface section, and the secondside includes a third angled surface section and a fourth angled surfacesection distinct from the third angled surface section.

Embodiment 10

A method of screening downhole fluids comprising: directing the downholefluids axially along a sand screen; passing the downhole fluids across aplurality of filter features that extend angularly outwardly of andaxially along the sand screen; establishing a selected fluid velocity ofthe downhole fluid based on at least an angle of the plurality of filterfeatures and particulate in the downhole fluids; and guiding a portionof the particulate through openings defined between the plurality offilter features while excluding another portion of the particulate.

Embodiment 11

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overlouvers defined by raised portions that extend outwardly from an outersurface of a tubular at an angle of between about 5° and about 45°.

Embodiment 12

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overraised portions that extend outwardly from an outer surface of a tubularat an angle of between about 15° and about 30°

Embodiment 13

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids intoa compound outer surface portion including an angled surface portionthat extends outwardly from an outer surface of a tubular at an angle ofbetween about 5° and about 45°.

Embodiment 14

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids intoan outer surface portion having a compound surface including an angledsurface portion that extends outwardly from an outer surface of atubular at an angle of between about 15° and about 30°.

Embodiment 15

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overan outer surface portion of a wire wrap having a compound surfaceincluding a first angled surface portion and a second angled surfaceportion, the first angled surface portion being at an angle of betweenabout 5° and about 45° relative to the second angled surface portion,the flow of fluids passing from the second angled surface portiontowards the first angled surface portion.

Embodiment 16

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overan outer surface portion of a wire wrap having a compound surfaceincluding a first angled surface portion and a second angled surfaceportion, the first angled surface portion being at an angle of betweenabout 15° and about 30° relative to the second angled surface portion,the flow of fluids passing from the second angled surface portiontowards the first angled surface portion.

Embodiment 17

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overan outer surface portion or a wire wrap having a compound surfaceincluding a first angled surface portion and a second angled surfaceportion, the first angled surface portion being at an angle of betweenabout 5° and about 45° relative to the second angled surface portion,the flow of fluids passing from the first angled surface portion towardsthe second angled surface portion.

Embodiment 18

The method of any prior embodiment, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overan outer surface portion of a wire wrap having a compound surfaceincluding a first angled surface portion and a second angled surfaceportion, the first angled surface portion being at an angle of betweenabout 15° and about 30° relative to the second angled surface portion,the flow of fluids passing from the first angled surface portion towardsthe second angled surface portion.

Embodiment 19

The method of any prior embodiment, wherein passing the downhole fluidsacross the plurality of filter features creates a bean-up protocolestablishing a tangential flow that passes into openings of the sandscreen.

Embodiment 20

The method of any prior embodiment, wherein the tangential flow directsfines in the downhole fluid into openings and excludes larger particlesfrom the openings without creating an impermeable filter cake at thesand screen.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. Further, it should further be noted that the terms “first,”“second,” and the like herein do not denote any order, quantity, orimportance, but rather are used to distinguish one element from another.The modifier “about” used in connection with a quantity is inclusive ofthe stated value and has the meaning dictated by the context (e.g., itincludes the degree of error associated with measurement of theparticular quantity).

The teachings of the present disclosure may be used in a variety of welloperations. These operations may involve using one or more treatmentagents to treat a formation, the fluids resident in a formation, awellbore, and/or equipment in the wellbore, such as production tubing.The treatment agents may be in the form of liquids, gases, solids,semi-solids, and mixtures thereof. Illustrative treatment agentsinclude, but are not limited to, fracturing fluids, acids, steam, water,brine, anti-corrosion agents, cement, permeability modifiers, drillingmuds, emulsifiers, demulsifiers, tracers, flow improvers etc.Illustrative well operations include, but are not limited to, hydraulicfracturing, stimulation, tracer injection, cleaning, acidizing, steaminjection, water flooding, cementing, etc.

While the invention has been described with reference to an exemplaryembodiment or embodiments, it will be understood by those skilled in theart that various changes may be made and equivalents may be substitutedfor elements thereof without departing from the scope of the invention.In addition, many modifications may be made to adapt a particularsituation or material to the teachings of the invention withoutdeparting from the essential scope thereof. Therefore, it is intendedthat the invention not be limited to the particular embodiment disclosedas the best mode contemplated for carrying out this invention, but thatthe invention will include all embodiments falling within the scope ofthe claims. Also, in the drawings and the description, there have beendisclosed exemplary embodiments of the invention and, although specificterms may have been employed, they are unless otherwise stated used in ageneric and descriptive sense only and not for purposes of limitation,the scope of the invention therefore not being so limited.

What is claimed is:
 1. A sand screen comprising: a tubular having anouter surface; and a plurality of filter features arranged on thetubular and defining a plurality of openings, each of the plurality offilter features being defined by a plurality of louvers having an angledsurface portion that extends axially along the tubular.
 2. The sandscreen according to claim 1, wherein the plurality of louvers include aplurality of raised portions that define a corresponding plurality ofopenings.
 3. The sand screen according to claim 2, wherein the pluralityof raised portions extend at an angle of between about 5° and about 45°relative to the outer surface of the tubular.
 4. The sand screenaccording to claim 3, wherein the plurality of raised portions extend atan angle of between about 15° and about 30° relative to the outersurface of the tubular.
 5. A sand screen comprising: a tubular having anouter surface; and a plurality of filter features arranged on thetubular and defining a plurality of openings, the plurality of filterfeatures being defined by a wire wrap having an outer surface portionhaving a compound surface including an angled surface portion thatextends axially along the tubular.
 6. The sand screen according to claim5, wherein the compound surface of the outer surface of the wire wrapincludes an outer surface portion having a first angled surface portionand a second angled surface portion, the second angled surface portionextending at an angle of between about 5° and about 45° relative to thefirst angled surface portion.
 7. The sand screen according to claim 6,wherein compound surface of the outer surface of the wire wrap includesan outer surface portion having a first angled surface portion and asecond angled surface portion, the second angled surface portionextending at an angle of between about 15° and about 30° relative to thefirst angled surface portion.
 8. The sand screen according to claim 6,wherein the wire wrap includes an inner surface portion, a first sideextending between the inner surface portion and the outer surfaceportion, and a second side extending between the inner surface portionand the outer surface portion.
 9. The sand screen according to claim 8,wherein the first side includes a first angled surface section and asecond angled surface section distinct from the first angled surfacesection, and the second side includes a third angled surface section anda fourth angled surface section distinct from the third angled surfacesection.
 10. A method of screening downhole fluids comprising: directingthe downhole fluids axially along a sand screen; passing the downholefluids across a plurality of filter features that extend angularlyoutwardly of and axially along the sand screen; establishing a selectedfluid velocity of the downhole fluid based on at least an angle of theplurality of filter features and particulate in the downhole fluids; andguiding a portion of the particulate through openings defined betweenthe plurality of filter features while excluding another portion of theparticulate.
 11. The method of claim 10, wherein directing the downholefluids along the sand screen includes directing the downhole fluids overlouvers defined by raised portions that extend outwardly from an outersurface of a tubular at an angle of between about 5° and about 45°. 12.The method of claim 11, wherein directing the downhole fluids along thesand screen includes directing the downhole fluids over raised portionsthat extend outwardly from an outer surface of a tubular at an angle ofbetween about 15° and about 30°.
 13. The method of claim 10, whereindirecting the downhole fluids along the sand screen includes directingthe downhole fluids into a compound outer surface portion including anangled surface portion that extends outwardly from an outer surface of atubular at an angle of between about 5° and about 45°.
 14. The method ofclaim 13, wherein directing the downhole fluids along the sand screenincludes directing the downhole fluids into an outer surface portionhaving a compound surface including an angled surface portion thatextends outwardly from an outer surface of a tubular at an angle ofbetween about 15° and about 30°.
 15. The method of claim 10, whereindirecting the downhole fluids along the sand screen includes directingthe downhole fluids over an outer surface portion of a wire wrap havinga compound surface including a first angled surface portion and a secondangled surface portion, the first angled surface portion being at anangle of between about 5° and about 45° relative to the second angledsurface portion, the flow of fluids passing from the second angledsurface portion towards the first angled surface portion.
 16. The methodof claim 10, wherein directing the downhole fluids along the sand screenincludes directing the downhole fluids over an outer surface portion ofa wire wrap having a compound surface including a first angled surfaceportion and a second angled surface portion, the first angled surfaceportion being at an angle of between about 15° and about 30° relative tothe second angled surface portion, the flow of fluids passing from thesecond angled surface portion towards the first angled surface portion.17. The method of claim 10, wherein directing the downhole fluids alongthe sand screen includes directing the downhole fluids over an outersurface portion or a wire wrap having a compound surface including afirst angled surface portion and a second angled surface portion, thefirst angled surface portion being at an angle of between about 5° andabout 45° relative to the second angled surface portion, the flow offluids passing from the first angled surface portion towards the secondangled surface portion.
 18. The method of claim 17, wherein directingthe downhole fluids along the sand screen includes directing thedownhole fluids over an outer surface portion of a wire wrap having acompound surface including a first angled surface portion and a secondangled surface portion, the first angled surface portion being at anangle of between about 15° and about 30° relative to the second angledsurface portion, the flow of fluids passing from the first angledsurface portion towards the second angled surface portion.
 19. Themethod of claim 10, wherein passing the downhole fluids across theplurality of filter features creates a bean-up protocol establishing atangential flow that passes into openings of the sand screen.
 20. Themethod of claim 19, wherein the tangential flow directs fines in thedownhole fluid into openings and excludes larger particles from theopenings without creating an impermeable filter cake at the sand screen.